Process of making artifical marble and stone



, UNITED STATES PATENT OFFICE.

o'rro Kant, or DEB mourns, IOWA.

PROCESS OF EAKITIG ARTIFICIAL BIABBLE AND STONE.

Io Drawing." Application flied June a, 1924. Serial No. 722,586.

The object of my invention isto provide uct that it can be accomplishedby mixing a process of making rtifical marble, stone, with the. liquid solution, one ounce of sugar tile or th like, in which the process can be to each gallon of water and one pound of carried out conveniently and economically. potassium chlorate.

6 Still a further object is to provide in the The liquid solution is added to the cement 6!! process, a method of giving to the plastic and silica, and mixed thoroughly therewith material from which the marble, sto e, or until the entire mass comes to a consistency tile is to be formed, the desired so where it can be poured from a container; that it resembles with a great degree of A flat table or support with a finel accuracy, a natural slab of marble or piece polished surface is then provided and IIlOltZ' 60 of ro k, p ings are placed around the table at any Still a further object is to provide the desired so that the mixture, when poured process of manufacturing artificial marble will make a slab of any desired size.

or stone, which will not only give a. similar I have found, in actual practice that it is appearance, but will also closely resemble quite desirable; to use. a glass surface for 0 the smoothness and have the qualities of the bed of the mold, and non-corroding, hardness that is found in natural marble highly polished metal bars for the sides of or rock. i the mold.

Still a further object is to cover or coat The plastic material, when poured from the plastic material with a liquid solution the supporting surface, is then leveled off by 7 containing sanderac, for giving to the a suitable bar or roller, and before the matefinished piece of marble or rock, a highly rial completely hardens, it can be cut into polished -surface. slabs of various sizes and shapes.

The process of manufacturin the artificial The cutting of the slab into smaller pieces marble, stone or the like wifi now be set can be best accomplished after the entire 7 forth in detail. mass has been permitted to set for about In the commercial use of my improved thirty minutes. process, I use Keenes cement and silica thoroughly mixed together. I have found Veimng gtep 3 that two parts of Keenes cement and one In order to make artificial marble, it is I art of silica is the proper mixture for givnecessary that the surface which is to ing suflicient hardness to the resulting prodexposed, be colored so as to look like natural not, and at the same time, will give a finish marble and at the same time, have the veins as will closely resemble the natural product. in i that are ordinarily found in natural It may be here mentioned that marble marble. v dust may be used in place of silica. The vem ng mixture consists of Keens The Keenes cement and silica, after becement, silica, water as above set out mixed ing properly mixed together, are then mixed to a very thin consi n y.

with a liquid solution consisting of water Thin strips of cloth or threads of twine in .which has been dissolved potassium. are then dipped into the thin mixture and chlorate, run across the surface of the bed of the The potassium chlorate and water are mold. I

used in the proportions of one gallon water The main body of the mixture is then to one pound potassium chlorate. The poured into the mold.

potassium chlorate is dissolved in hot water Various colors of mixture can be used at and the solution shouldbe mixed with the the same time for giving to the marble, a mixture of Keenes cement and silica, while blended effect so that it more nearly resemit is yet hot. bles true natural marble.

I have found that in case a highly polish- The entire mixture can be colored if deed surface is desired on the resulting prodsired-,aor the exposed surface only colored.

more than a The veining material, which is nothing thin mixture colored,can be (lashed or sprayed in position so as to give a greater and more accurate blended effect to the finished product.

The thickness of the artificial marble or stone can be varied as desired.

It requires from about eight to twelve hours to permit the mass to dry so that it can be conveniently handled.

The surface of the material resting upon the glass or other smooth bed of the mold will be highly polished when removed.

I have found that the tensile strength of the material, when it becomes hard, is even better than natural marble and there is not the danger of cracking that there is in the natural marble. I

The product that I make by my process, after it becomes hardened will not warp.

If a stone with a dull surface is desired, then the sugar is omitted from the solution and the mass or mixture is removed from the molds before it is completely -set and dry. The removing of the material before. it is completely set will give a dull finish to the exposed surface.

It ma be here mentioned that the entire mass, a ter poured into the mold should be given a vibrator movement in order to cause any air poc ets within the mixture to come to the top.

The marble or tile slabs so formed can be used for wall finishing or door finishing just like natural marble.

Powder form.

It may be here mentioned that the. inredients may be all mixed in powdered form and shipped in bags, and then mixed with water by the manufacturer of the artificial marble or rock.

It may also be mentioned that the powplaced upon a rough cement floor prepared for the purpose, and

then troweled smoothly for giving to they floor a hard surface.

When the mixture is in dry form it consists of seventy pounds of Keenes cement, thirty pounds of silica or marble dust, ten pounds of potassium chlorate, and coloring matter of any suitable color depending upon the shade of color desired, twelve ounces of sugar in case a highly polished surface is desired.

The above mixture, when in powdered form, should be mixed with hot water until it reaches a paste-like consistency so that it can be poured and used. This may be used upon a wall, as ordinary plaster and there will give to the wall a hard finish.

The mixture, when it has set for sometime, can be then coated with sandarac dissolved in alcohol. I have found that twelve ounces of sandarac dissolved in one gallon of "3. The process of gether of Keenes form, adding thereto potassium chlorate "ing the thin highly polished mold and neeoses alcohol will give me a very fine coating that can be sprayed iipon the surface of the marble or rock, and will make it retain a highly polished surface. 7

Some changes may be made in the ste s of my rocesswithout departing from t e essential part and purpose of my invention.

1' claim as my invention: l. The process of manufacturing artificial marble or the like comprising the mixing togather of Keenes cement and silica in dry form, adding thereto potassium chlorate dissolved in hot water and while so formed is still hot until a paste like consistency is had, pouring of the mixture upon a highly polished surfaced mold.

- e process of manufacturing artificial marble or the like comprising the mixing toether of Keenes cement and silica in dry orm, adding thereto potassium chlorate and sugar dissolved in hotwater and while the solution so formed is still hot until a paste like consistency is bad, pouring of the mixture upon a highly polished surfaced.

mold;

manufacturing artificial marble or the like comprisingthe mixing together of Keenes cement and silica indry form, adding thereto potassium chlorate dissolved in hot water and while the solution so consistency is had, forming of veins by smear' g a thin colored mixture over the molding surface of ahighly polished mold and then pouring smeared surface.

4-; The process of manufacturing artificial marble or the like comprising the mixing tocement andsilica in dry dissolved in hot water while the solution so formed is still hot, until a paste like consistence is had, forming veins by smearing a thin colored mixture by use of a rag havcolored mixture therein and it over the molding surface of a then pouring the mixture upon said smeared surface.

drawing 5. The process of manufacturing artificial marble or the like comprising the mixing togcther of Keenes cement and silica-in dry orm, adding thereto potassium chlorate dissolved in hot water and'while the solution so formed is still hot until a paste like consistency is had, forming of veins by use of a rag impregnated with a coloredthin solution of the mixture itself and smearing it over a mold before the mixture is poured and then pouring the mixture thereover for givin a natural appearance to the resulting pro uct. 6. The process of manufacturing artificial marble or the like comprising the mixing together of Keenes cement. and silica in dry form, adding thereto potassium chlorate disthe solution the mixture upon said 1 formed is still hot, until a paste like ice llld

are

solved in hot water and while the" solution so formed is still hot until a paste like consistency is had, forming of veins in the resulting product by use of a rag impregnated with a colored thin solution of the mixture itself and smearing it over a mold before the mixture is poured and then pouring the mixture thereover for giving a natural appearance to the and spraying resulting product the resulting product with 1 a highly polished surface. Des Moines, Iowa, June 16, 1924. OTTO KELL. 

